0398047 JOHNSON POWERHEAD GASKET SET

Table 1
Revision Table
Revision Summary of Changes
01 Added serial numbers. Important Safety Section
Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If the tools, the procedure, the work method, or your actions are not recommended by Caterpillar, ensure that the tools and your actions are safe for you and for others.Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel should be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.
Note: Always use proper eye protection when performing any mechanical repairs to a vehicle including, but not limited to, any installation and or repairs to the starter. Failure to use proper eye protection can lead to serious and permanent eye damage.Note: Only perform the mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical capabilities should be handled by a professional installation specialist.Note: Follow engine and/or vehicle manufactures instruction carefully when removing and installing the starters. Disassembly procedures for replacing brush package and/or brush plate.Note: Always disconnect battery ground before removing or replacing cables at the starter. Failure to disconnect the battery ground cable can lead to serious injury.Installation Procedure
Perform the below procedures to install/replace the 8T-8570 Brush Holder As and 7T-3278 Brush Holder As.
Remove vehicle leads connected to the starter, note their positions for reinstallation of starter, and remove starter.
Remove clip from Over Crank Protection (OCP) connector, if applicable.
From the insulated/ground terminal, carefully note the orientation, remove all parts including the solenoid ground lead. Check the condition of insulators and sealing features and consider replacing them, if they are damaged or excessively worn.
Remove the four CE screws and CE housing. If replacing the brush plate, proceed to step 6.
If only replacing the brushes, remove the four brush springs, four brush screws, and four brushes. This also releases the ground terminal and lead assembly. Proceed to reassembly step 1.
Remove the bush-plate with the four brushes and four Brush springs. Proceed to reassembly step 2.Reassembly Procedures for Brush Package
Install the four brush springs, ensuring they are in the same position as removed. This can be accomplished with needle nose pliers or special tools. Install the brush springs using the tool and hit smoothly on it, once the spring is directed on track, hit or press on the spring face until it is completely seated. This tool, made from a screwdriver with the same outside diameter as the brush springs first inside diameters turn. The cutoff end has an offset slot with the slot depth being about half or 2/3rd the width of the spring. The offset slot fits inside the first turn of the spring.
Install the brush plate assembly into the frame assembly, using the pins to align and install one brush at a time, pulling the spring to allow them to get into the holder, assuring the same position as removed.
Install ground terminal and lead assembly. Attach the terminal’s negative leads and negative brush leads to the brush plate with two screws. Tighten the screws to 2.3 to 4.5 N m (20.4 to 40.0 lb in).
Attach the positive brush and field leads to the brush plate with two of the brush screws. Tighten the screws to 2.3 to 4.5 N m (20.4 to 40.0 lb in).
Install the square fiber insulator onto the ground stud.
Apply bearing type grease onto CE housing’s inner diameter where the frame O’ring is seated and apply a small amount of SAE20 oil into the bushing area.
Install CE housing over the locator pins and CE screws, ensuring the square fiber washer is properly aligned